Glueless pocketed spring unit construction

ABSTRACT

Methods and systems for no-glue pocketed spring unit construction. Rows of pocketed springs, preferably arranged into modules of more than two pocketed springs surrounding a central hole, are ultrasonically welded together when paired vibrating probes and anvils press layers of pocketed spring fabric from the rows of pocketed springs together and a welding pulse is transmitted to the vibrating probe.

CROSS-REFERENCE

Priority is claimed from U.S. Provisional App. No. 61/754,529 filed Jan.19, 2013, which is hereby incorporated by reference.

Priority is claimed from U.S. Provisional App. No. 61/757,075 filed Jan.25, 2013, which is hereby incorporated by reference.

BACKGROUND

The present application relates to methods and systems for no-glueconstruction of pocketed inner spring units, and more particularly tomethods and systems for using ultrasonic heating to construct pocketedinner spring units.

Note that the points discussed below may reflect the hindsight gainedfrom the disclosed inventions, and are not necessarily admitted to beprior art.

Connecting rows of pocketed springs together using a scrim sheetgenerally causes a trampoline-like effect, i.e., compressing springs inone part of the unit pulls on another part of the unit.

Glue connections between pocketed springs generally provide a“crunchier” feeling to a completed pocketed spring unit than connectionsmade by ultrasonic welding.

SUMMARY

The inventor has discovered surprising new approaches to methods andsystems for manufacturing glueless pocketed spring cushioning units foruse in mattresses and other cushioning assemblies. Rows of pocketedsprings preferably comprise multi-pocketed spring modules, springshaving uniform coil diameter, ones of said modules comprising more thantwo pocketed springs welded together to leave a central opening. Rows ofpocketed springs are retained in position by pins, and are transferredto corresponding rows of vibrating probes and anvils which pinch layersof fabric together and form welds using ultrasonic vibrational energy.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed inventions will be described with reference to theaccompanying drawings, which show important sample embodiments and whichare incorporated in the specification hereof by reference, wherein:

FIG. 1 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 2 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 3 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 4 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 5 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 6 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 7 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 8 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 9 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 10 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 11 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 12 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules to each other.

FIG. 13 schematically shows an example of a mattress which has a core ofmany pocketed spring units which are mechanically joined togetherwithout glue, using a process like that shown in FIGS. 1-12.

FIG. 14 shows an example of a process for welding rows of pocketedspring modules together.

DETAILED DESCRIPTION OF SAMPLE EMBODIMENTS

The present application discloses new approaches to constructingpocketed spring units. In particular, the inventor has developed varioussystems and methods for NO-GLUE construction of pocketed spring units.

The disclosed innovations, in various embodiments, provide one or moreof at least the following advantages. However, not all of theseadvantages result from every one of the innovations disclosed, and thislist of advantages does not limit the various claimed inventions.

-   -   pocketed spring unit construction uses NO GLUE;    -   pocketed spring units, and cushioning assemblies incorporating        pocketed spring units, are more comfortable and        luxurious-feeling;    -   cost-effective ultrasonic welding of rows of pocketed springs;    -   none of the connections in pocketed spring units are glue        connections;    -   pocketed spring unit construction is less expensive;    -   stronger connections between rows of pocketed springs;    -   reduced environmental impact of pocketed spring unit        construction;    -   reduced environmental impact of cushioning assembly construction        and maintenance;    -   reduced weight of pocketed spring unit;    -   reduced weight of cushioning assembly;    -   lower cushioning assembly transportation cost per unit;    -   reduced likelihood of unmoored pockets;    -   reduced likelihood of loose springs.

The numerous innovative teachings of the present application will bedescribed with particular reference to presently preferred embodiments(by way of example, and not of limitation). The present applicationdescribes several inventions, and none of the statements below should betaken as limiting the claims generally.

“Cushioning assembly” and “cushioning unit” are defined herein as anycushioning structure incorporating pocketed springs, e.g., a mattress,couch or cushion.

In preferred embodiments, pockets are formed gluelessly byultrasonically welding together layers of a flexible material, generallyplastic, such as spun bonded polypropylene weighing 1.5 ounces persquare yard. By forming pockets of a chosen size on a chosen length andwidth of fabric, rows of pockets of a chosen length and sized for achosen diameter and length of spring can be produced.

In preferred embodiments, uniform diameter springs are used. Uniformdiameter springs can be manufactured by custom winding high tensilestrength wire with highly uniform shape and thickness.

Some embodiments use or include microcoil springs, which are smallsprings suitable for use in pocketed spring units incorporated into, forexample, upholstery.

Springs are inserted into pockets to form pocketed springs. Springs canbe inserted into pockets oriented horizontally through a seam on top ofthe pocket, and then beaten until they reorient vertically. Generally,this results in a pocketed spring that, in a completed cushioningassembly, can only be oriented in a single direction. For example, a bedmade in this way is typically called “one sided”.

Springs can also be inserted oriented vertically through a seam on theside and allowed to expand to fill the pocket.

Pockets can be fashioned to be shorter than an uncompressed spring, sothat pocketed springs are constantly under load (“preloaded”). Thisgenerally increases the useful lifetime of the spring, by allowing itsspring constant to remain higher, for longer. Preloaded springs aregenerally inserted vertically compressed, and allowed to expandvertically to fill the pocket.

A row of pocketed springs, in which pocketed springs are connected toadjacent pocketed springs (e.g., by the same fabric that forms thepockets) can be formed as shown and described in, for example, U.S. Pat.No. 6,260,331.

Rows of pocketed springs can be fashioned into rows of multi-pocket“modules”, comprising more than two—generally, four—pockets weldedtogether to leave an opening (a hole) in the middle. Rows of modules canthen be ultrasonically welded together, and those rows can then bewelded to each other to form pocketed spring units. Pocketed springmodules can be assembled as shown and described in, for example, U.S.Pat. No. 6,347,423. Preferably, nearest-adjacent (not catty-corner)springs in modules have uniform spacing from each other.

Multiple horizontally-adjacent rows of pocketed springs can be connectedtogether to form pocketed spring cushioning units. Generally, pocketedspring units look like arrays of pocketed springs from above.

Springs in completed pocketed spring units are compressed very flat androlled up into tight cylinders for shipping.

Glue can be used in layers of a cushioning assembly manufactured asdisclosed herein other than the inventive pocketed spring cushioningunit layer(s).

FIG. 1 schematically shows a machine 100 for ultrasonically welding rowsof pocketed spring modules 200 to each other. In FIG. 1, the machine isin an initial position, without pocketed spring modules 200. Two rows ofupward-facing vertical positioning pegs 102 are disposed to penetrateholes 104 in a liftable table 106, are attached to a stable surface 108beneath the liftable table 106, and are configured to hold two rows ofpocketed spring modules 200 in position (see, e.g., FIG. 2). Rows ofpegs 102 are aligned so that a line through a row of pegs 102 isperpendicular to a line between two nearest pegs 102 in two differentrows. (The left-most row of pegs 102 and row of pocketed spring modules200 in the figures will be called herein the “front” rows, and theright-most rows will be called the “far” rows.)

As shown in FIG. 1, the front row of downward facing phalanges are thevibrating probes 110 (also called horns), and the far-most row ofdownward facing phalanges are anvils 112. Advantageously, the probes 110and the anvils 112 are spaced at approximately the same intervals as theupward-facing pegs 102, and are positioned so that when they are moved(e.g., on a rail system 114, as shown) front-wards to their front-mostposition, they vertically align with the pegs 102.

The bottom-most (approximately) inch of the vibrating probes 110 (the“active region”) is configured to vibrate at a frequency suitable forcompressing and heating the plastic fabric of the pockets to a pressureand temperature suitable for welding together multiple layers (generallytwo or more layers) of said plastic fabric. (A weld can be performed on,e.g., four layers, such as if the modules 200 are formed from pairs ofrows of pocketed springs welded together, and the rows of pocketedsprings are pocketed in pockets formed from a long single sheet offabric doubled over width-wise).

Preferably, the active region of a vibrating probe 110 is located on itsside, i.e., a horizontally-facing edge (at, part of or including wherethe vibrating probe 110 presses against the anvil 112). This simplifiesthe mechanical operation of the vibrating probes 110 and anvils 112inserting into the central openings in individual modules 200 andpressing together, with spring pocket fabric between, so that thecontact region and the active region overlap, allowing welding in thecontact region.

Welding occurs when the vibrating probes 110 and the anvils 112 movetogether, and the active regions of the vibrating probes 110 and afacing surface of corresponding anvils 112 press flush against eachother with the layers of fabric to be welded between them. The vibratingprobe 110 is then activated with a welding pulse at a (1) frequency, (2)energy level and (3) amount of pressure against the anvil 112 tuned toweld the particular density and thickness of plastic fabric of thepockets. The vibrating probes 110 and anvils 112 can be pushed togetherby, e.g., a rail system 116 (as shown in FIG. 1, a rail system 116 usingair actuators separate from the rail system 114 that moves the vibratingprobes 110 and anvils 112 front-ward and far-ward together). Vibrationscan be provided by transducers 118 integrated into the mechanism, asshown in FIG. 1 above the vibrating probes 110. Generally, vibrations ofvertically-oriented probes 110 will be primarily horizontal.

Spacing of pegs 102, vibrating probes 110 and anvils 112 can beadjustable to correspond to module 200 diameter and hole 104 placement.

The table 106 through which the pegs 102 are disposed includes a liftmechanism 120 to push the liftable table 106 upwards; the upward-movingtable 106 pushes upwards any rows of pocketed spring modules 200disposed on the pegs 102. The lift mechanism 120 shown in FIG. 1comprises servo motors 122. The table 106 also includes an extractorplate 124, described in more detail with respect to FIGS. 8 and 10.

FIG. 2 schematically shows a machine 100 for ultrasonically welding rowsof pocketed spring modules 200 to each other. In embodiments as shown inFIG. 2, rows of pocketed spring modules 200 are disposed on, andspatially aligned by, the pegs 102. Here, pocketed spring modules 200comprise four pocketed springs. Preferably, two rows of pocketed springsare welded together to form modules 200 prior to the modules beingloaded onto the machine 100, allowing entire rows of modules to betreated as individual, separate units.

Module holes 202 are aligned with pegs 102, and rows of modules 200 aredropped or pushed onto corresponding rows of pegs 102. Advantageously,springs within the pockets are of uniform size, and modules 200 arespaced a uniform distance from each other. Uniform sizing can beadvantageously enhanced by using springs made from high tensile wire ofeven thickness and consistent shape, and by using substantially the samelength of wire to form each coil.

FIG. 3 schematically shows a machine 100 for ultrasonically welding rowsof pocketed spring modules 200 to each other. As shown in FIG. 3, thevibrating probes 110 and anvils 112 move leftward together to bevertically aligned over the pegs 102, and thus also over the holes 202described by the middles of the pocketed spring modules 200.

FIG. 4 schematically shows a machine 100 for ultrasonically welding rowsof pocketed spring modules 200 to each other. As shown in FIG. 4, thetable 106 pushes the rows of modules 200 upwards, partially off the pegs102 and (correspondingly) partially onto the vibrating probes 110 andanvils 112 disposed above, and vertically aligned with, the pegs 102.

FIG. 5 schematically shows a machine 100 for ultrasonically welding rowsof pocketed spring modules 200 to each other. As shown in FIG. 5, thevibrating probes 110 and anvils 112 push the fabric between them—andbetween two corresponding pairs of pocketed springs in different rows ofpocketed spring modules 200—together. When a suitable pressure has beenachieved, a welding pulse of vibration is sent through the vibratingprobes 110, heating the fabric to the point of melting together thelayers of fabric compressed by respective vibrating probes 110 andanvils 112. The vertical position of the active region of the vibratingprobe 110 during welding corresponds to the vertical position of theweld.

FIG. 6 schematically shows a machine for ultrasonically welding rows ofpocketed spring modules 200 to each other. As shown in FIG. 6, thevibrating probes 110 and anvils 112 have separated to their horizontalpositions as shown in FIG. 4, and the liftable table 106 has risenhigher (than in FIG. 5), pushing the rows of pocketed spring modules 200almost entirely onto the corresponding vibrating probes 110 and anvils112 and off of the pegs 102.

FIG. 7 schematically shows a machine 100 for ultrasonically welding rowsof pocketed spring modules 200 to each other. As shown in FIG. 7, thevibrating probes 110 and anvils 112 are pushed together again to performanother weld as described in FIG. 5. The pocketed spring modules 200 canremain approximately aligned with the pegs 102 during this portion ofthe procedure.

Welds can be overlapped, e.g., for greater strength. Generally, thevibrating probes and anvils can place welds anywhere along a verticalline on the pocket fabric. Further, the strength of said welds istunable by controlling welding pulse (1) frequency, (2) energy level and(3) amount of vibrating probe pressure against the corresponding anvil.Different numbers and vertical placements of weld positions can also beused to control use characteristics, such as firmness, of the resultingcushioning unit.

FIG. 8 schematically shows a machine 100 for ultrasonically welding rowsof pocketed spring modules 200 to each other. In FIG. 8, the vibratingprobes 110 and anvils 112 have moved, pushing the now welded togethermodules 200 so that the openings in the frontward row of modules 200 arealigned over the far row of pegs 102. This places a far edge (or more)of the far row of pocketed spring modules 200 (as shown in FIG. 8, therow of modules 200 currently on the row of anvils 112) under theextractor plate 124. The vibrating probes 110 and anvils 112 can performa weld during or at the beginning (or prior) or end (or after) of thismovement.

The extractor plate 124 has holes 126 corresponding to the locations ofthe vibrating probe 110 and the anvil 112; as shown in FIGS. 8 and 9,the holes 126 partially or fully surround the anvils 112 and/or thevibrating probes 110 when a front row of modules 200 is in position tobe transferred to the far row of pegs 102.

FIG. 9 schematically shows a machine 100 for ultrasonically welding rowsof pocketed spring modules 200 to each other. In FIG. 9, the vibratingprobes 110 and anvils 112 have separated and moved back to theiroriginal relative position, with the vibrating probes 110 now locatedover the far row of pegs 102.

FIG. 10 schematically shows a machine 100 for ultrasonically weldingrows of pocketed spring modules 200 to each other. The liftable table106 is connected to, and rises and falls with, the extractor plate 124,which is oriented approximately parallel to the liftable table 106. Whenthe table is lowered as shown in FIG. 10, the extractor plate 124 lowerstoo, pushing the now-joined rows of pocketed spring modules 200 off thevibrating probe 110 and the anvil 112, and pushing the holes 202 of thefront row of pocketed spring modules 200 onto the far row of pegs 102(as explained above, the vibrating probes 110 were located over the pegs102 in FIG. 9). A crank 128 can be used to adjust the height of theliftable table 106 to correspond to the height of the pocketed springmodules 200.

FIG. 11 schematically shows a machine 100 for ultrasonically weldingrows of pocketed spring modules 200 to each other. In FIG. 11, a new rowof pocketed spring modules 200 has been placed on the front row of pegs102 by positioning the holes 202 of the modules 200 over the pegs 102and dropping or pushing the row of modules 200 onto the pegs 102.

FIG. 12 schematically shows a machine 100 for ultrasonically weldingrows of pocketed spring modules 200 to each other. In FIG. 12, thevibrating probes 110 and anvils 112 have moved to vertically align withthe front and rear rows of pegs 102, respectively. This point in theprocess corresponds to FIG. 3, but with one far-most (right-most) row ofpocketed spring modules 200 already welded to the middle row of pocketedspring modules 200 with a number of no-glue connections.

FIG. 13 schematically shows a mattress 1300. Generally, a mattress 1300comprises a core 1302, upholstery and a fabric cover (typically calledticking). The core 1302 provides support for a user, upholstery cushionsthe core 1302, and the fabric cover is wrapped around the core 1302 andupholstery and contributes both aesthetics and texture to the surface ofthe mattress 1300.

In preferred embodiments, the core 1302 comprises many pocketed springunits 1304. The upholstery can also comprise pocketed spring units, suchas pocketed microcoil spring units.

FIG. 14 shows an example of a process for welding rows of pocketedspring modules 200 to each other. Pocketed spring modules 200 are loadedonto rows of pegs 102 in step 1400. Paired vibrating probes 110 andanvils 112 (preferably arranged in rows) are positioned over the pegs102 to receive the modules 200 in step 1402. The liftable table 106 thenpushes the modules 200 partially or fully onto the vibrating probes 110and anvils 112 in step 1404, and the vibrating probes 110 and anvils 112are pressed closed, with pocket material pressed between them, in step1406. If a weld is planned for this vertical position on the pocketmaterial 1408, a welding pulse is transmitted to the vibrating probes110 and the modules 200 are welded together at this vertical position.Otherwise 1408, the welding pulse is skipped. If the modules 200 are notfully lifted onto the vibrating probes 110 and anvils 112 at step 1412,the process repeats from step 1404.

If the modules 200 are fully lifted 1412, the vibrating probes 110 andanvils 112 (still closed together) move the modules 200 to a dropoffposition, and the vibrating probes 110 and anvils 112 then open (moveapart) 1414. Once the dropoff position is reached and the vibratingprobes 110 and anvils 112 have opened such that the vibrating probes 110are vertically aligned with the far row of pegs 102, the extractor plate124 pushes the modules 200 onto the pegs 102 in step 1416. If thecushioning unit is planned to have more rows of modules 200 welded on(is not complete) 1418, then a new row of modules 200 is added to thefront row of pegs 102 at step 1420, and the process repeats from step1402. If the cushioning unit is complete 1418, then the process ends1422. The cushioning unit can then be removed from the assemblymechanism (if necessary).

Alternatively, if the cushioning unit is complete at step 1414, step1414 can move the modules to a dropoff position away from pegs, so thatthe cushioning unit can easily be removed from the assembly mechanismfollowing (or as a result of) step 1416.

According to some but not necessarily all embodiments, there isprovided: A method for glueless assembly of cushioning units,comprising: a) inserting one of at least one probe/anvil pair intoopenings in a first continuous row of connected multiple-coil modules,and inserting the other of said probe/anvil pair into openings in asecond continuous row of connected multiple-coil modules; whereinindividual ones of said modules comprise more than two pocketed springswhich together surround one of said openings; and wherein individualones of said pocketed springs each comprise a spring inside a pocketmade of a flexible material; b) moving said probe/anvil pair together,and applying acoustic power to said probe, to thereby weld said firstand second rows of multiple-coil modules together at one or morelocations; c) removing at least one of said first and second rows ofmodules from said probe/anvil pair; and repeating said steps (a), (b)and (c) until more than two rows of modules have been thereby weldedtogether to form a cushioning structure having an extended area.

According to some but not necessarily all embodiments, there isprovided: A method for glueless assembly of cushioning units,comprising: putting openings of first and second rows of pocketed springmodules onto first and second rows of locator pins respectively; whereinindividual ones of said pocketed spring modules comprise more than twopocketed springs which together surround one of said openings; andwherein individual ones of said pocketed springs each comprise a coilspring inside a pocket made of a flexible material; transferring saidfirst and second rows of pocketed spring modules from said first andsecond rows of locator pins onto a double row of probe/anvil pairs;moving the probe and anvil of ones of said probe/anvil pairs together,and welding said first and second rows of pocketed spring modulestogether by applying acoustic power to said probes; and repeating saidmoving and welding steps on said first and second rows of pocketedspring modules at multiple different coaxial positions, to thereby formwelding at multiple vertical positions on said first and second rows ofpocketed spring modules.

According to some but not necessarily all embodiments, there isprovided: A method for glueless assembly of cushioning units,comprising: putting first and second rows of pocketed springs onto firstand second rows of locator pins respectively; wherein individual ones ofsaid pocketed springs each comprise a coil spring in a pocket made of aflexible material; transferring said first and second rows of pocketedsprings from said first and second rows of locator pins onto a doublerow of probe/anvil pairs; and moving the probe and anvil of ones of saidprobe/anvil pairs together, and applying acoustic power to said probesto thereby weld said first and second rows of pocketed springs together.

According to some but not necessarily all embodiments, there isprovided: A method for glueless assembly of extended area cushioningunits, comprising the steps of repeatedly: loading first and second rowsof pocketed springs onto first and second rows, respectively, of locatorpins; wherein individual ones of said pocketed springs each comprise acoil spring in a pocket made of a flexible material; welding said firstand second rows of pocketed springs together, with a relative alignmentdetermined by said first and second rows of locator pins; loading saidfirst row of pocketed springs onto said second row of locator pins, andloading an additional row of pocketed springs onto said first row oflocator pins; and repeating said welding step to weld said first row ofpocketed springs together with said additional row of pocketed springs.

According to some but not necessarily all embodiments, there isprovided: A method for glueless assembly of cushioning units,comprising: putting openings of first and second rows of pocketed springmodules onto first and second rows of locator pins respectively; whereinindividual ones of said pocketed spring modules comprise more than twopocketed springs which together surround one of said openings; andwherein individual ones of said pocketed springs each comprise a coilspring inside a pocket made of a flexible material; transferring saidfirst and second rows of pocketed spring modules from said first andsecond rows of locator pins onto a row of probe/anvil pairs using alifting table, and using said probe/anvil pairs to ultrasonically weldsaid first and second rows of modules together; moving said row ofprobe/anvil pairs, with said first and second rows of modules still inplace thereon, into a dropoff position; and pushing said first andsecond rows of modules off of said row of probe/anvil pairs, using anextractor plate which generally surrounds ones of said probe/anvilpairs.

According to some but not necessarily all embodiments, there isprovided: A method for glueless assembly of cushioning units, comprisingthe steps of repeatedly: welding rows of pocketed spring modulestogether using vibrating probes and anvils; wherein individual ones ofsaid pocketed spring modules comprise more than two pocketed springswhich together surround an opening; and wherein individual ones of saidpocketed springs each comprise a coil spring inside a pocket made of aflexible material; and repeating said welding step on successive rows ofmodules to form a cushioning structure having an extended area, in whichadjacent modules are welded together in both length and width directionsof the cushioning structure; wherein said welding step is performeddifferently, in different operations, to provide a variable verticalextent of welding, for a given height of the pocketed springs, toprovide a selected degree of firmness in the cushioning structure.

According to some but not necessarily all embodiments, there isprovided: A method of assembling an extended area cushioning structurecomprising: (a) pocketing a plurality of coil springs inside a flexiblematerial, at least some individual ones of said coil springs beinglocated in separate pockets which are separated from each other andformed into linear connected rows of pocketed coil springs by welds insaid flexible material; (b) welding together pairs of said linearconnected rows of pocketed coil springs to form linear connected rows ofmodules; wherein individual ones of said modules comprise more than twopocketed springs which together surround an opening; and (c) repeatedlywelding together pairs of said linear connected rows of modules tothereby form a cushioning support structure having an extended area, inwhich adjacent modules are welded together in both length and widthdirections of the cushioning support structure; (d) wherein individualones of said pocketed coil springs are joined together, in the center ofsaid support structure, by polymer welds, and not by glue.

According to some but not necessarily all embodiments, there isprovided: A method for glueless assembly of cushioning units,comprising: arranging two or more adjacent rows of multiple side-by-sideconnected pocketed springs of uniform coil size, ones of said pocketedsprings comprising a spring in a pocket made of a flexible material,corresponding springs in adjacent ones of said rows being arrangedside-by-side; and closing together and activating multiple welding pairsof vibrating probes and anvils at multiple locations substantiallysimultaneously, ones of said activated welding pairs ultrasonicallywelding pocket material between two adjacent pairs of pocketed springsfrom two different ones of said rows.

According to some but not necessarily all embodiments, there isprovided: A method of making a mattress, comprising: assembling a coreby welding rows of pocketed spring modules together without glue;wherein individual ones of said pocketed spring modules comprise morethan two pocketed springs which together surround an opening; andwherein individual ones of said pocketed springs each comprise a coilspring inside a pocket made of a flexible material; and repeating saidwelding step on successive rows of modules to form a cushioning supportstructure having an extended area, in which adjacent modules are weldedtogether in both length and width directions of the cushioning supportstructure; and padding said core with upholstery, and wrapping saidpadded core with a fabric cover.

According to some but not necessarily all embodiments, there isprovided: A method of making a mattress, comprising: assembling anupholstery by connecting without glue multiple rows of multiple pocketedmicrocoil springs, ones of said pocketed microcoil springs comprising amicrocoil spring in a pocket made of a flexible material, said rows ofpocketed microcoil springs being connected by welds formed usingultrasonic vibrational energy, said welds being located with variablevertical weld extent on said flexible folding material between saidpockets; and padding a core with said upholstery, and wrapping saidpadded core with a fabric cover.

According to some but not necessarily all embodiments, there isprovided: A mechanism for glueless assembly of pocketed units,comprising: (a) at least first and second adjacent and mutually parallelrows of locator pins configured to position two or more adjacent rows ofpocketed spring modules; wherein individual ones of said pocketed springmodules comprise more than two pocketed springs which together surroundan opening; and wherein individual ones of said pocketed springs eachcomprise a coil spring inside a pocket made of a flexible material; and(b) one or more welding pairs of vibrating probes and contact prongsconfigured to receive said rows of pocketed spring modules from saidlocator pins and to close together to compress and ultrasonically weldpocket material between two adjacent pairs of pocketed springs from twodifferent rows of pocketed spring modules.

According to some but not necessarily all embodiments, there isprovided: A mechanism for glueless assembly of pocketed spring units,comprising: at least one vibrating probe and at least one anvil having anoncontact portion and a contact portion, said contact portion parallelto and configured to press flush against said vibrating probe duringultrasonic welding, said noncontact portion configured to be distal fromsaid vibrating probe when said contact portion and said vibrating probeare pressed flush, said vibrating probe and said anvil configured to berelatively moveable, wherein two rows of pocketed spring modules arewelded together when layers of pocket fabric corresponding to both ofsaid rows of pocketed spring modules are pressed between said vibratingprobe and said contact portion and a welding pulse is transmitted tosaid vibrating probe.

According to some but not necessarily all embodiments, there isprovided: A mechanism for glueless assembly of pocketed inner springunits, comprising: at least two rows of locator pins which protrudethrough a lifting table; a double row of probe/anvil pairs, saidprobe/anvil pairs configured to press flush together in a weldingposition, and to create welds between multiple layers of flexible springpocket material compressed between said probe/anvil pairs when a weldingpulse is passed through said vibrating probes when in said weldingposition; said lifting table configured to transfer multiple rows ofpocketed spring modules from said locator pins to said probe/anvilpairs; wherein individual ones of said pocketed spring modules comprisemore than two pocketed springs which together surround an opening; andwherein individual ones of said pocketed springs each comprise a coilspring inside a pocket made of said material; and an extractor plateconfigured to transfer said rows of pocketed spring modules off of saidprobe/anvil pairs.

According to some but not necessarily all embodiments, there isprovided: A mechanism for glueless assembly of cushioning units,comprising: at least one probe/anvil pair, one of said probe/anvil pairconfigured to be inserted into openings in a first row of modules, andthe other of said probe/anvil pair configured to be inserted intoopenings in a second row of modules; wherein individual ones of saidmodules comprise more than two pocketed springs which together surroundone of said openings; and wherein individual ones of said pocketedsprings each comprise a spring inside a pocket made of a flexiblematerial; a transporter, configured to move said probe/anvil pairstogether and apart, and between module pickup and module dropoffpositions; a lifter, configured to pickup said first and second rows ofmodules onto said probe/anvil pairs; an extractor, configured to dropoffsaid first and second rows of modules from said probe/anvil pair at amodule dropoff position after said first and second rows of modules arewelded together; and an acoustic power source, configured to applyacoustic power to said probes when said probe/anvil pairs are movedtogether, to thereby weld said first and second rows of modules togetherat one or more locations.

According to some but not necessarily all embodiments, there isprovided: A cushioning structure comprising: a plurality of coil springspocketed inside a flexible folding material, at least some individualones of said coil springs being located in separate pockets which areseparated from each other by welds in said flexible material and areformed into linear connected rows of pocketed coil spring modules;wherein individual ones of said modules comprise more than two pocketedcoil springs which together surround an opening; and a plurality of saidrows being connected into a single extended unit to provide a supportstructure which is wider than any of said rows; wherein individual onesof said rows are welded together, in the center of said supportstructure, completely without glue.

Modifications and Variations

As will be recognized by those skilled in the art, the innovativeconcepts described in the present application can be modified and variedover a tremendous range of applications, and accordingly the scope ofpatented subject matter is not limited by any of the specific exemplaryteachings given. It is intended to embrace all such alternatives,modifications and variations that fall within the spirit and broad scopeof the appended claims.

As used herein and as is apparent from the disclosure set forthhereinabove, “left” and “right” (and “front” and “far”) are arbitraryterms signifying generally opposing directions, respectively orientedtowards pre-weld (generally, welding machine entrance) and post-weld(generally, welding machine exit) pocketed spring module positions asshown in FIGS. 1-12.

In some embodiments, the vibrating probes and anvils start in differentpositions than shown in FIG. 1.

In some embodiments, probe/anvil pairs move the rows of modules over toa dropoff position once the modules are fully off of the pegs; in someembodiments, once the modules are fully loaded onto the probe/anvilpairs; in some embodiments, at some (or any) time between.

In some embodiments, a pocketed springs in a row of pocketed springs maybe connected to each other by material other than the material used toform pockets.

In some embodiments, pocketed springs may be formed by welding pocketedsprings to a strip or strips of flexible material (e.g., the materialused to form pockets).

In some embodiments, different lengths or portions of the vibratingprobe may be tuned to comprise the active welding portion.

In some embodiments, rows of pocketed spring modules can beautomatically fed onto rows of pegs.

In some embodiments, rows of pocketed spring modules can be manually fedonto rows of pegs.

In some embodiments, the vibrating probes and anvils are moved leftwardand rightward together (or separately) by the same transportation systemthat pushes them together and apart for welding.

In some embodiments, lifting mechanisms other than servo motors are usedto lift the liftable table, such as hydraulic motors.

In some embodiments, other transportation types (than rails) and motortypes are used to move the vibrating probes left-wards and right-wards,and together and apart, than described hereinabove.

In some embodiments, the vibrating probe moves to the anvil to pressflush against the anvil prior to welding.

In some embodiments, the anvil moves to the vibrating probe to pressflush against the vibrating probe prior to welding.

In some embodiments, the vibrating probe and anvil both move to pressflush against each other prior to welding.

In some embodiments, vibrating probes have more than one active region.In some embodiments with vibrating probes with more than one activeregion, a single welding pulse can be used to perform more than one weldsimultaneously (i.e., a weld caused by more than one active region on avibrating probe). In some embodiments with vibrating probes with morethan one active region, vibrating probes have an active region proximalto their top and an active region proximal to their bottom. In someembodiments with vibrating probes with more than one active region,multiple welds, in multiple vertical positions, caused by a singlewelding pulse, can securely hold two modules together.

In some embodiments, the probes and/or anvils push the modules into adropoff position while the probes and anvils are separated from eachother (open).

In some embodiments, something other than the probes and/or anvils(e.g., a pusher rod or plate) moves the modules into a dropoff position

Particular left/right orientations of the vibrating probe and anvil havebeen described and shown with respect to the disclosed inventions. Itwill be apparent to one of ordinary skill in the arts of machineengineering of manufacturing machinery that alternative orientations ofprobe/anvil pairs are possible; e.g., reversed orientation, or at +/−30degrees from the front-ward/far-ward axis of the welding machine (thelatter orientation(s), for example, to weld rows of hexagonal 6-pocketedspring modules together), or orthogonally to a feed axis of the weldingmachine (e.g., to weld disjoint subrows of modules together).

It will also be apparent to said person of ordinary skill that doublerows of probe/anvil pairs need not be fully segregated (i.e., that a rowcan consist of both probes and anvils).

In some embodiments, probe/anvil pairs can be arranged otherwise than inorderly rows.

In some embodiments, one or more probe/anvil pairs can be configured toopen and close at different times from other probe/anvil pairs.

In some embodiments vibrations of vertically-oriented probes will behorizontal along approximately the same axis as formed by the line ofvibrating probes (e.g., approximately orthogonal to both thefront-ward/far-ward axis and the vertical axis of a machine as picturedin FIGS. 1-12).

In some embodiments, different probe/anvil pairs can be caused to weldat different vertical positions.

In some embodiments, for some welding events, some of the probes are nottransmitted a welding pulse.

In some embodiments, probe/anvil pairs can close at different times fromeach other.

In some embodiments, different probes can be transmitted differentwelding pulses (e.g., to create different strength welds).

Particular up/down orientations have been described hereinabove withrespect to, e.g., the lifting table and extractor plate. It will beapparent to one of ordinary skill in the arts of machine engineering ofmanufacturing machinery that alternative orientations (rather than alonga z axis) are possible.

In some embodiments, the springs are in the pockets prior to welding.

In some embodiments, three or more rows of pocketed springs are weldedtogether substantially simultaneously.

In some embodiments welding three rows together substantiallysimultaneously, two pairs of vibrating probe and anvil perform welds ata given horizontal position; in other such embodiments, an anvil movessequentially to two different vibrating probes at a given horizontalposition; in other such embodiments, a vibrating probe movessequentially to two different anvils at a given horizontal position.

In some embodiments, a weld is performed while the vibrating probes andanvil are moving relative to the rows of pegs.

In some embodiments in which the upholstery comprises rows of pocketedmicrocoil springs, the core can be of a type other than pocketedsprings, e.g., continuous coils.

In some embodiments, rows of modules comprise disjoint subrows ofmodules, such that two disjoint subrows of modules are not connected toeach other.

In some embodiments using disjoint subrows of modules, disjoint subrowscomprising a first row are connected to each other when they are weldedto a full row of modules, or welded to a subrow of modules that isdisjoint from other subrow(s) of modules comprising a correspondingsecond row at a location that is not aligned with the disjunction(s) inthe first row.

In some embodiments using disjoint subrows of modules, disjoint subrowsare connected to form a non-disjoint row of modules by welding pocketfabric of disjoint subrows at the location of the disjunction.

In some embodiments, a row of pocketed springs (not modules) isconfigured to be positioned by pegs and welded to another row ofpocketed springs (not modules); for example, using openings described bycylinders (open at top and bottom) or rings formed from excess pocketedspring fabric, or welded onto the rows of pocketed springs. In some suchembodiments, each said row of pocketed springs is itself a doubled rowof pocketed springs.

In some embodiments, the liftable table comprises only sufficientstructure to transfer the rows of modules from the locator pins to theprobe/anvil pairs, or is a continuous structure except where penetratedby locator pins, and can generally be anything between (e.g., a set ofparallel strips, or strips in a criss-cross pattern, or any other shapeor pattern capable of pushing rows of modules from the locator pins ontothe probe/anvil pairs). In some embodiments, rows of modules aresupported by a stationary or separately movable resting table inaddition to or instead of the liftable table when the liftable table isat a position where rows of modules are fully loaded onto the locatorpins (or at a lowest position).

Preferably one “module” of pocketed springs includes exactly fourpocketed springs which totally surround a vertical opening which extendsfor the full height of a pocketed spring. However, in alternative andless preferred embodiments, more or fewer pocketed springs can be usedto define a single module.

In some embodiments, pocketed spring modules comprise pocketed springshaving uniform coil-to-coil distance in a length direction of thecushioning unit, and different uniform coil-to-coil distance in a widthdirection of the cushioning unit.

While ultrasonic welding is the currently preferred and most provenembodiment, other techniques can be used to weld the pocketed springstogether. For one example, it is contemplated that induction heating canbe used to provide localized spot heating—and hence, under pressure,welding—of the two layers of flexible material which are being heldtogether by the probe and anvil. For another example, the probe andanvil can be used as conductors for simple ohmic heating. The locationwhere the probe and anvil have pinched two layers of flexible materialbetween them can be analyzed as a metal-insulator-metal (MIM) capacitor,and superficial modification can be performed to generate localizedohmic heating at the contact areas of the probe and/or anvil.

The pockets which will contain the springs can be formed, for example,from a continuous strip of folded polymer material. Welds are formedacross this strip to separate the pockets from each other. As notedabove, the pockets preferably have openings on their sides where aflattened coil spring can be inserted and released; once the coil springis allowed to expand into the pocket, its ends will stay at the ends ofthe pocket.

Two such strips can then be welded together at every other weldlocation. This produces a strip of modules, where each module includesfour pocketed spring units surrounding an opening. Such a strip ofmodules is shown in FIG. 2 and the following figures.

Optionally the strip of modules can be trimmed to the desired width (orlength) of the finished structure before the steps of FIGS. 1-12 areperformed. However, alternatives are possible, as will be readilyrecognized by those of ordinary skill in the arts of machine engineeringof manufacturing machinery.

In some embodiments, alternative shapes can be used for the extractorplate, such as multiple extractor fingers, or an extractor rod parallelto the table and to the axis formed by a row of modules (i.e., from oneend of the row to the other end of the row).

In some embodiments, a far edge (or more) of a front row of moduleslocated on the vibrating probes is under the extractor plate when thefront row of modules is in position to be transferred to the far row ofpegs.

In some embodiments, the extractor plate is shaped to push on differentportions of the front and far rows of modules than described above.

In some embodiments, a manual or automated mechanism other than a crankcan be used to control the height of the table. In some embodiments, acrank or other mechanism can be used to control the height of theextractor plate.

In some embodiments, multiple welds for rows of modules are performedsubstantially simultaneously; in some embodiments, welds for said rowsare (or can be) performed sequentially.

In some embodiments, pockets have insertion slots in the side.

In some embodiments, pocket material is a sheet of flexible polymer.

In some embodiments, coil springs have non-uniform (but known) diameter.

In some embodiments, coil springs have non-uniform (but known) spacingfrom each other.

In some embodiments, all rows of modules are transferred from the pegsto the vibrating probes and anvils substantially simultaneously.

In some embodiments, pegs are steel, and have approximatelyfrustroconical tips.

In some embodiments, the liftable table and extractor plate can moveseparately.

In some embodiments, the extractor plate is mechanically connected tothe liftable table at an adjustable distance therefrom.

Additional general background, which helps to show variations andimplementations, may be found in the following publications, all ofwhich are hereby incorporated by reference: U.S. Pat. No. 5,772,100;U.S. Pat. No. 3,844,869; U.S. Pat. No. 4,234,983; U.S. Pat. No.4,401,501; U.S. Pat. No. 6,131,892; U.S. Pat. No. 6,260,331; U.S. Pat.No. 6,347,423; U.S. Pat. No. 6,101,697; U.S. Pat. No. 6,021,627; U.S.Pat. No. 5,613,287; U.S. Pat. No. 5,553,443; U.S. Pat. No. 4,439,977;U.S. Pat. No. 4,485,506; U.S. Pat. No. 5,749,133; U.S. Pat. No.5,613,287; U.S. Pat. No. 4,986,518; U.S. Pat. No. 4,906,309; U.S. Pat.No. 4,854,023; U.S. Pat. No. 4,523,344; U.S. Pat. No. 4,234,984; U.S.Pat. No. 3,251,078; U.S. Pat. No. 2,540,441; U.S. Pat. No. 1,226,219;U.S. Pat. No. 1,192,510; and U.S. Pat. No. 685,160; and published U.S.patent applications 20120311784, 20120091644, 20110191962, 20110107572,20100218318, 20100212090, and 20080245690.

Additional general background, which helps to show variations andimplementations, as well as some features which can be implementedsynergistically with the inventions claimed below, may be found in thefollowing US patent applications. All of these applications have atleast some common ownership, copendency, and inventorship with thepresent application, and all of them, as well as any material directlyor indirectly incorporated within them, are hereby incorporated byreference: U.S. Pat. No. 6,131,892; U.S. Pat. No. 6,260,331; and U.S.Pat. No. 6,347,423.

None of the description in the present application should be read asimplying that any particular element, step, or function is an essentialelement which must be included in the claim scope: THE SCOPE OF PATENTEDSUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none ofthese claims are intended to invoke paragraph six of 35 USC section 112unless the exact words “means for” are followed by a participle.

The claims as filed are intended to be as comprehensive as possible, andNO subject matter is intentionally relinquished, dedicated, orabandoned.

What is claimed is:
 1. A method of making a mattress, comprising:assembling a core by welding rows of pocketed spring modules togetherwithout glue; wherein said modules comprise two rows of pocketed springswelded together between non-consecutive pairs of said pocketed springs;wherein individual ones of said pocketed spring modules comprise morethan two pocketed springs which together surround an opening; andwherein individual ones of said pocketed springs each comprise a coilspring inside a pocket made of a flexible material; and repeating saidwelding step on successive rows of modules to form a cushioning supportstructure having an extended area, in which adjacent modules are weldedtogether in both length and width directions of the cushioning supportstructure; and padding said core with upholstery, and wrapping saidpadded core with a fabric cover.
 2. The method of claim 1, wherein saidrows of modules are formed by welding two rows of pocketed springstogether, and wherein the pockets of ones of said rows of pocketedsprings are formed from a single sheet of said flexible material.
 3. Themethod of claim 1, wherein adjacent modules are welded together in bothlength and width directions of the mattress.
 4. The method of claim 3,wherein said welds in both length and width directions of the mattresscomprise welds between rows of said pocketed springs to form said rowsof modules, and said welds between rows of modules formed by saidwelding step.
 5. The method of claim 1, wherein said modules comprisepocketed springs having uniform coil size and coil-to-coil distance.